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Old 05-24-2013
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Re: Hitachi Alternator rebuild instructions

I got it apart last night.

It's difficult to disassemble because there is a tight press fit between the bearing and housing and the bearing and spindle. I had to use a gear puller to pull the front cover off, then improvise a pusher to push the rear housing off. Heating the rear housing (it is aluminum) would probably be a better approach, you just have to be careful not to cook the lube in the bearing. The bearings are standard industrial sizes and I had spares, so I replaced them.

One brush is connected to the L terminal (already exposed). The other brush (and the one that I appear to need) is not connected to anything externally accessible, so I needed to add a wire and route it through the back.

The brushes on this don't have real retainers, but there are loops of wire behind the brush housing that can be used to retract them during reassembly.
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